NHTSA ID Number: 10115362
Manufacturer Communication Number: IK0800503
TSB/Document Date: 2017-08-16
Summary
ISB Starting System Diagnostics
IK0800503 ISB Starting System Diagnostics
Page 1 of 5
Countries:
CANADA, UNITED STATES Document ID: IK0800503
Availability:
ISIS, Bus ISIS, FleetISIS
Revision:
5
Major System:
ELECTRICAL SYSTEM
Created:
10/22/2014
Current Language: English
Last Modified: 5/11/2015
Other Languages: NONE
Author:
Viewed:
David Horner
2081
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Title : ISB
Starting System Diagnostics
Applies To : ISB Engine
CHANGE LOG
04/27/2015 Updated SRT's, repaired hyperlinks within diagnostic steps
04/02/2015 Removed flexplate face to face measurement and updated diagnostic steps. Added ring gear damage acceptance chart and image for
voltage check
01/22/2015- Changed flexplate face to face depth measurement replacement guideline to measurement with no action required
12/05/2014- Inserted flexplate face to face depth measurement replacement guideline10/23/2014 Initial Article Release
DESCRIPTION
This document will guide the user through Cummins ISB starter and ring gear diagnostics. It is important to review all the material to
prevent repeat failures, especially in instances of ring gear damage by the starter.
SYMPTOMS
Diagnostic Trouble Codes
DTC/Light
Description
N/A
Customer Observations or Concerns:
Operator may hear one of the following from the starter:
•
•
•
•
•
•
•
•
•
Click
Clunk
Grind
Squeal
Starter spins, doesn't rotate engine
Slow Engine Crank
Click No-Crank
No-Click No-Crank
Crank No-Start
SPECIAL TOOLS / SOFTWARE
Tool Description
Cummins Insite
Tool Number
Comments
Instructions
Cummins Tool
Midtronics ESP
DVOM
Obtain Locally
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IK0800503 ISB Starting System Diagnostics
Page 2 of 5
Tools Resource Center
SERVICE PARTS INFORMATION
Kit Description
Part Number
Quantity
MOTOR,STARTING 12V , 38MT DELCO 8201039
1
Flexplate (Automatic Transmission)
1
3968672
Notes
Order Critical Truck
Down Next Day Air
Order from Cummins
DIAGNOSTIC STEPS
Step Action
Diagnostic Trouble Code Check:
1
Decision
Yes. Go to appropriate diagnostic manual
to diagnose crank no start symptom
Review current health report for Cummins or Body Controller fault codes that may
cause an extended crank condition (Crankshaft Position Sensor, Camshaft Sensor,
Fuel System, Electrical codes)
No. Step 2
Are there pending/active/previously active DTC's causing a crank no start?
Step Action
Cranking RPM Test:
2
Decision
Yes. Go to appropriate Cummins crank no
start diagnostic
Monitor Engine RPM using Cummins Insite while cranking the engine
No. Step 3
Does the engine crank at ~150RPM or more during the check?
Step Action
Manual Engine Barring Test:
3
Decision
Yes. Step 4
Have an assistant bar the engine over from the alternator pulley
No. Diagnose engine lock up condition.
Does the engine rotate freely?
Step Action
Perform battery test:
Decision
Yes. Replace ONLY failed battery and
then recheck for symptom
Before testing batteries, inspect each cable end nut torque, insulation, routing,
clipping, discoloration, and terminal arching
4
Follow IK0800482- Battery Testing, Diagnostics & Maintenance
Save screenshot of results (IK2700003- Midtronics Screen Print)
No. Step 5
Is a warranty approval code (WAC) or failed battery result from any battery
generated?
Step Action
5
Starter Cable Voltage Drop Test:
Decision
Yes. Make required repair
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IK0800503 ISB Starting System Diagnostics
Page 3 of 5
No. Step 6
Before performing any voltage drop test; inspect each cable end nut torque,
insulation, routing, clipping, discoloration, and terminal arching
Follow Midtronics starter cable voltage drop test (Chapter 7 Page 33)
Save screenshot of results (IK2700003- Midtronics Screen Print)
Does the Starter Cable Voltage Drop Test fail?
Step Action
Alternator Cable Voltage Drop Test:
Decision
Yes. Make required repair
Before performing any voltage drop test; inspect each cable end nut torque,
insulation, routing, clipping, discoloration, and terminal arching
6
Follow Midtronics alternator cable voltage drop test (Chapter 7 Page 34)
No. Step 7
Save screenshot of results (IK2700003- Midtronics Screen Print)
Does the Alternator Voltage Drop Test fail?
Figure 1: Starter IMS S terminal DVOM Hookup Location
Step Action
7
Starter Control Circuit Check:
Decision
Yes. Perform starter control diagnostics
for possible causes:
Before performing Starter Control Circuit Check; inspect each wire end nut torque,
insulation, routing, clipping, discoloration, and terminal arching.
Wiring
F3A Fuse
Connect DVOM test leads on IMS (Mag switch) "S terminal" and ground to solenoid Start Relay (Neutral Relay)
case as indicated in Figure 1 while having an assistant hold keyswitch in start
Crank Inhibit Relay
position for 5 seconds.
Clutch Switch (Manual Trans)
Trans Control Module (Auto Trans)
Compare DVOM to B+ at batteries
Key Switch
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IK0800503 ISB Starting System Diagnostics
Page 4 of 5
No. Step 8
Does the DVOM not read battery voltage +/-0.5 volts?
Figure 3: Flexplate/Flywheel Ring Gear Acceptance
Step Action
Decision
Yes. Step 9
Flexplate/Flywheel Ring Gear Inspection:
Remove starter
Mark the flexplate ring gear with a paint pen
8
Have an assistant bar the engine over while you inspect each tooth for damage:
burrs, milling, chips, etc. (Figure 3)
No. Inspect each tooth
Tip: This can be done as a one man operation using a borescope or by looking
through the starter mount hole
Did all 127 teeth get inspected?
Step Action
9
Decision
Repair:
Yes Replace flexplate & starter
Does the flexplate need to be replaced?
No Replace starter
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IK0800503 ISB Starting System Diagnostics
Page 5 of 5
WARRANTY INFORMATION
Any of the following symptoms should be documented in notes on the warranty claim
Click
Clunk
Grind
Squeal
Slow engine crank
Click nocrank
No-click no-crank
Crank nostart
Warranty Claim Coding:
Group: 08540- Cranking System
Noun: 202- Motor, Starter
Standard Repair Times:
Description
Chassis
SRT
Hours
Starter Diagnostics
CE Bus
Cummins ISB
GY08-2202A
0.9
Starter Diagnostics
4300
Cummins ISB
KL08-2202A
0.9
Starter Motor Replacement CE Bus
Cummins ISB
GY08-4202SB 0.8
Starter Motor Replacement 4300
Cummins ISB
KL08-4202SB 1.1
CE Bus
Cummins ISB
GY13-9114SB 3.2
4300
Cummins ISB
KL13-9114SB 3.2
Flexplate Replacement
CE Bus
GY13-9114SB
0.3
1
Flexplate Replacement
4300
Cummins ISB
KL13-9114SB0.3
1
Automatic Transmission
(Removal & Reinstall)
Automatic Transmission
(Removal & Reinstall)
OTHER RESOURCES
Master Service Information Site
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Copyright © 2015 Navistar, Inc.
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TSB/Document ID: IK0800503
Replacement Service Bulletin Number:
MFR Communication Date: 2015-05-11
MFR Internal Campaign ID/Software Version:
Communication Type: Service Bulletin/Repair Instructions
NHTSA Components: ENGINE
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